Reinforced glass-ceramic article and enamel suitable for the coating thereof

ABSTRACT

A process for reinforcing a glass-ceramic article, into which a maximum tension is introduced beneath the surface of the glass-ceramic, advantageously in proximity to said surface. The invention also relates to an enamel that can be used for this reinforcement, this enamel being formed from a glass frit having the following composition, the proportions being expressed as weight percentages: 
                                       SiO 2     50-66%          MgO   3-8%         Na 2 O   7-15%          K 2 O   0-3%         Li 2 O   0-12%          CaO   0-10%          BaO   0-15%          Al 2 O 3     0-3%         ZrO 2     0-3%         ZnO   0-5%         B 2 O 3     0-8%                                         
the sum of the alkaline-earth metal oxides CaO+BaO moreover being between 8 and 15%, and the sum of the alkali metal oxides Na 2 O+K 2 O+Li 2 O moreover being between 7 and 20%. The reinforced glass-ceramics obtained by the process.

The present invention relates to an article (substrate, product) made ofglass-ceramic, in particular a glass-ceramic plate, intended, forexample, for covering or accommodating heating elements, such as forexample a hob, an oven door, or a chimney insert, or a fire screen,etc., to a process for obtaining said article, and to a novel enamelcomposition suitable for the coating thereof. More particularly, thepresent invention relates to a mechanically reinforced glass-ceramicarticle and also to the process of reinforcing a glass-ceramic articleand/or to the enamel that makes it possible to obtain said reinforcedglass-ceramic article.

Sales of articles such as glass-ceramic hobs have been continuing togrow over the last few years. This success is explained in particular bythe attractive appearance of such hobs and by the ease of cleaning them.

It will be recalled that a glass-ceramic is originally a glass, calledprecursor glass (or mother glass. or green glass), the specific chemicalcomposition of which allows controlled crystallization to be induced bysuitable heat treatments, called ceramization. This partly crystallizedspecific structure gives the glass-ceramic unique properties.

At the present time, there are various types of glass-ceramic plate,each variant being the result of extensive research and many tests,given that it is very difficult to make modifications to these platesand/or to the process for obtaining them without risking an unfavorableeffect on the desired properties. In particular, to be able to be usedas a hob, a glass-ceramic plate must generally have a transmission inthe wavelengths of the visible range that is both low enough to mask atleast some of the subjacent heating elements when not in use and highenough so that, depending on the case (radiant heating, inductionheating, etc.), the user can, for the sake of safety, visually detectthe heating elements when they are in operation and/or can, whereappropriate, read the displays. It must also have a high transmission inthe wavelengths of the infrared range, especially in the case of hobswith radiant burners.

The glass-ceramic plates must also have a sufficient mechanical strengthas demanded in their field of use (for example, in accordance with theEN 60335-2-6 standard for hobs in the field of household electricalgoods). In particular, in order to be able to be used as hobs, theglass-ceramic plates must have sufficient resistance to the pressure andto the shocks that may arise (support and dropping of utensils, etc.).Generally, the glass-ceramic plates alone have a mechanical strengththat is expressed in particular by a scale factor (defined below)between 150 and 180 MPa.

Most current plates are of dark color, in particular black, but thereare also plates of lighter color (in particular white having, forexample, a haze of at least 50%, as described in patent FR 2 766 816),or even transparent plates provided with opacifying coatings. Amongknown (functional and/or decorative) coatings for glass-ceramic plates,there are conventionally enamels, based on glass frits and pigments, andcertain paints resistant to high temperature, based for example on alkydresins. In particular, enamels have the advantage of being able to bedeposited on the precursor glass (or mother glass or green glass) beforeceramization and of being able to be baked during the ceramization, andalso have the advantage of being able to withstand high temperatures(allowing the use of various heating means for the plate). However, theyhave the drawback of generally permitting only a single deposition (noenamel superposition is possible) and with a small thickness, otherwisethere is a risk in particular of the enamel flaking off and ofmechanically damaging the glass-ceramic plate. As regards paint, thismay be applied (if so required) as several layers. However, it must beapplied after ceramization (and therefore requires an additional bakingoperation) and remains limited to plates for induction burners(operating at lower temperature).

More recently, glass-ceramic plates have also been proposed withcoatings based on reflective layers deposited by magnetron sputtering orbased on glass batch materials incorporating special-effect pigments(aluminum oxide or mica flakes coated with metal oxides). However, thecoatings based on layers deposited by magnetron sputtering are moreexpensive since they require a specific installation and are generallylimited to plates for induction burners, and their manufacture, carriedout after ceramization, is more complex or tricky. As regards coatingsbased on a glass batch with special effect pigments, they have the samedrawbacks as the abovementioned enamels.

The object of the present invention was to provide improved novelglass-ceramic articles (such as plates), in particular to develop anenamel composition more suitable for the coating of glass-ceramics, thiscomposition not having, or having in a significantly more limitedfashion, the drawbacks of enamel compositions currently used forglass-ceramics, in particular to embrittle the glass-ceramic as littleas possible, while retaining the advantages linked to the use of anenamel, and also, where appropriate, a sufficient opacity. By so doing,the present invention is not only oriented toward the development ofunembrittled glass-ceramic articles, but has moreover enabled theproduction of reinforced glass-ceramic articles through the developmentof a process that aims to improve the mechanical strength of theglass-ceramic articles.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1: The thickness stress profile in the glass-ceramic of referenceexample 3, which includes the case of the bare (uncoated) glass-ceramicplates.

FIG. 2: The thickness stress profile in the glass-ceramic of example 1,which includes the case of the bare (uncoated) glass-ceramic plates.

FIG. 3: The thickness stress profile in the glass-ceramic of example 2.

The present invention thus relates to a novel glass-ceramic article (orsubstrate), such as a plate, and a novel enamel for glass-ceramics, saidarticle being at least partly coated with at least one layer of saidenamel, this enamel comprising one (or being formed of one or from one)glass frit having the following (weight) composition, the proportionsbeing expressed as weight percentages (composition expressed as weightpercentages of oxides or else percentages by weight, based on theoxides, the constituents commonly being in this form in the enamelcompositions):

SiO₂ 50-66% and preferably 50-65% MgO 3-8% and preferably 4-8% Na₂O7-15% K₂O 0-3% Li₂O 0-12% CaO 0-10% BaO 0-15% and preferably 0-13% Al₂O₃0-3% and preferably 0-2% ZrO₂ 0-3% and preferably 0-2% ZnO 0-5% B₂O₃0-8% and preferably 0-7%

the sum of the alkaline-earth metal oxides CaO+BaO moreover beingbetween 8 and 15%, and preferably between 8 and 12%, and the sum of thealkali metal oxides Na₂O+K₂O+Li₂O moreover being between 7 and 20%, inparticular between 7 and 15%.

Preferably, the glass-ceramic article according to the invention is aglass-ceramic plate, intended, for example, for covering oraccommodating at least one heating element, in particular intended to beused as a hob or as a wall (in particular a door or part of a door) ofan oven, or as a chimney insert, or else as a fire screen.

The present invention relates simultaneously to the (mineral) glasshaving the composition defined above, used for the frit and that makesit possible to produce the improved enamel and article according to theinvention, the enamel thus produced, having a composition that(initially) contains the particles (or frit) of said glass, and also inits form obtained by baking said composition, and the glass-ceramicarticle coated (usually over part or all of one face) with said enamel.

The present invention also relates to a process for manufacturing anarticle, in particular a plate according to the invention, in which theabove composition is applied, preferably by screen printing, to theprecursor glass (or mother glass or green glass) article beforeceramization, said composition being baked during the ceramizationcycle, and/or in which the above composition is applied, preferably byscreen printing, to the glass-ceramic article after ceramization, thensaid composition is baked.

Advantageously, the glass-ceramic article, in particular theglass-ceramic plate, coated with the enamel according to the inventionhas an improved tensile strength (in particular compared to conventionalenameled plates). The tensile strength is measured using aring-on-tripod bending test, on an enameled plate test specimen havingdimensions of around 70 mm×70 mm (the thickness of the plate moreovergenerally being around 4 mm), the enameled face being elongated. Thetest specimen rests on three 9.5-mm diameter balls each positioned atthe vertices of an equilateral triangle inscribed in a 40-mm diametercircle. A force is applied by pressing at the center (the load beingisotropic in this region) of the test specimen with a 10-mm diameterring. The rate of advance of the ring is around 5 mm/min. The resultsare interpreted using the Weibull model described in the followingarticle: “A Statistical Theory of the Strength of Materials”, RoyalSwedish Institute For Engineering Research, W. Weibull, Stockholm 1939,1-45. The data obtained revealing the average rupture stress is the dataknown as the “scale factor”, expressed in MPa (this scale factor being,in other words, the result of the processing, by the Weibull method, offlexural modulus of rupture (MOR) measurements).

Thus, the glass-ceramic article, in particular the glass-ceramic plate,coated with the enamel according to the invention advantageously has ascale factor, obtained according to the Weibull model following abending test, of at least 130 MPa, in particular of at least 140 MPa, inparticular of at least 150 MPa, said factor possibly ranging up to 280MPa at least. This greater tensile strength is particularlyadvantageous, in particular under extreme transport and storageconditions, some conventional enameled plates being, in comparison,liable to break when a much smaller force is exerted (these plateshaving, for example, a scale factor of around 70 to 80 MPa, the scalefactor of non-enameled plates itself generally being around 150 to 180MPa). In this regard, it has in particular been possible to establish inthe present invention for the article coated with the enamel accordingto the invention that the crack formed during a shock is orientedparallel to the surface, possibly thus leading to high energydissipation and better mechanical strength. In particular, when theenamel is baked subsequently as specified below, the glass-ceramicarticle (such as the plate) obtained, coated with the enamel accordingto the invention, advantageously has a scale factor, obtained accordingto the Weibull model following a bending test, much greater than 180MPa, that is to say not only far above that of conventional enameledplates, but that even significantly exceeds that of bare (non-enameled)glass-ceramic plates, such mechanically reinforced glass-ceramicarticles preferably being targeted in the present invention.

The present invention also relates more generally to a process forreinforcing a glass-ceramic article, into which (or comprising a stepaccording to which) a maximum tension is introduced beneath the surfaceof the glass-ceramic, advantageously in proximity to said surface. Inother words, the glass-ceramic is treated so that the stress profile (ordistribution of the residual stresses) in the thickness of theglass-ceramic has a maximum tension (or maximum tensile stress value)beneath the surface of the glass-ceramic in proximity to this surface(in particular in the first quarter of the thickness starting from thetreated/reinforced surface) in at least one region (in particular thetreated region) of the glass-ceramic. The presence of a maximum tensionin the stress profile reveals, where appropriate, the presence offlexion in the glass-ceramic (in the case of example 2 and/or the caseof the use of an enamel according to the invention baked subsequently asdescribed below, the profile obtained being illustrated in FIG. 3) orthis maximum tension may be expressed, where appropriate, by a peak insaid profile (in the case of example 1 and/or in the case of the use ofan enamel according to the invention baked during the ceramization asdescribed below, the profile obtained being illustrated in FIG. 2). Acompression zone beneath the surface (in particular before the maximumtension going toward the surface) is also generally observed, thisshallow depth compression zone participating, in particular, in thereinforcement by forcing the cracks, formed where appropriate during ashock, to turn beneath the surface in order to be parallel to thesurface, and thus preventing the propagation of these cracks.

The reinforcement obtained by the process according to the invention isat least a relative reinforcement (compared to the same glass-ceramicsubstrate of the same thickness treated in a customary manner, forexample in the case, explained below, of the use of the enamel accordingto the invention where the glass-ceramics obtained are at least muchless embrittled/unembrittled/reinforced compared to glass-ceramicstreated with conventional enamels) and is preferably advantageously anabsolute reinforcement (compared to the same glass-ceramic of the samethickness, which is bare or untreated).

More particularly in the reinforcement process according to theinvention, at least one region of at least one face of the glass-ceramicis reinforced by introducing a maximum tension of at least 1.2 MPa, andpreferably of at least 1.5 MPa beneath the surface of the region/faceconsidered and in proximity to the latter. Preferably, the reinforcementis obtained by treating the glass-ceramic so that it has a (maximum)tensile stress of at least 1.2 MPa at a depth of at least 50 μm beneaththe/its surface, and preferably of at most 25% of the thickness of theglass-ceramic (for example the thickness of the plate in the case of aglass-ceramic plate) relative to the surface of the glass-ceramic, inthe region considered/treated, as mentioned previously. When the articlehas several faces, the reinforcement may be made on one or more parts orthe whole of one or more faces, and advantageously on at least the mainpart of one face, the reinforcement on a single face (the depth of themaximum tensile stress being determined from this face/surface)generally being sufficient. The thickness stress profile in theglass-ceramic and the maximum tension (tensile stress) are measuredusing a biasographe as described in the following work: “Photoelasticityof Glass”, H. Aben, C. Guillemet, Springer-Verlag Berlin Heidelberg1993, 126-129. They may also be measured using a polarizing microscopeequipped with a Babinet compensator (“Photoelasticity of Glass”, H.Aben, C. Guillemet, Springer-Verlag Berlin Heidelberg 1993, 65-66), eachoptical delay value (δ) given by the equipment (biasographe orpolarizing microscope) being converted to a stress value (σ) by using aBrewster constant (C) equal to 2.6 Brewster according to the equationσ=δ/(C×l), l being the width passed through by the light.

The present invention also relates to a glass-ceramic article (inparticular a glass-ceramic plate, intended, for example, for covering oraccommodating at least one heating element) reinforced, in particular onone face or part/region of one face (or on at least one face or part ofone face), characterized in that the glass-ceramic has a (maximum)tensile stress of at least 1.2 MPa, and preferably of at least 1.5 MPa,at a depth, beneath the surface (of said part of face or face), of atleast 50 μm (or more specifically the glass-ceramic has a stress profilein the thickness such that it has a (maximum) tensile stress of at least1.2 MPa at a depth of at least 50 μm) and preferably of at most 25% ofthe thickness of the glass-ceramic, relative to the surface of theglass-ceramic, in at least said region or face.

Preferably, (especially the case with the use of the enamel according tothe invention in particular baked subsequently), the reinforcedglass-ceramic article according to the invention, in particular thereinforced glass-ceramic plate, advantageously has (especially for thetreated/reinforced region) a scale factor, obtained according to theWeibull model following a bending test, greater than 180 MPa, thusexceeding that of bare glass-ceramic plates, and in addition has aWeibull modulus (revealing the dispersion of the results, the resultsbeing even less dispersed when the modulus is large) that isadvantageously high (greater than 15). The present invention thus makesit possible to obtain glass-ceramic articles having an improvedmechanical strength or to guarantee that a good mechanical strength isretained while reducing, for example, the thickness of the glass-ceramic(the reduction in thickness customarily being accompanied by anembrittlement of the glass-ceramic). In particular, the presentinvention enables glass-ceramic plates to be obtained that have athickness of around 3 mm (instead of 4 mm customarily) and that retain agood mechanical strength enabling them, in particular, to be used as ahob.

The present invention also relates to a process for manufacturing (such)a reinforced glass-ceramic article characterized in that it comprises areinforcing step as described previously.

The introduction of a maximum tension in the glass-ceramic in thereinforcing processes or step described previously may be carried out bya suitable treatment or coating, for example, and according to oneadvantageous embodiment of the invention, by the use of the enamelaccording to the invention, preferably baked subsequently, as explainedearlier. The reinforcement in the case of the use of such a coating isexpressed firstly by no embrittlement or a significantly reducedembrittlement of the glass-ceramic compared to that coated with aconventional coating of the same type (i.e., in the present case,compared to the glass-ceramic coated with a conventional enamel), andwhere appropriate is also advantageously expressed (the enamel accordingto the invention having been baked during the ceramization orsubsequently, the highest values being obtained in the case of bakingsubsequently) by an increase in the mechanical strength compared to thebare or untreated glass-ceramic).

The composition of the enamel according to the invention, capable ofreinforcing the glass-ceramic and defined above, will now be explainedmore precisely below. In this composition, the ranges defined for eachof the components are paramount for obtaining the desired properties,respect for these ranges making it possible in particular tosimultaneously guarantee the production of the frit at high temperature,good coating of the enamel on the substrate, the desired mechanicalstrength and the chemical resistance, etc.

As indicated above, the composition mentioned preferably comprises lessthan 2% of alumina Al₂O₃, and particularly preferably this compositionis alumina-free.

It should be noted that, besides the constituents mentioned above, thecomposition may, if necessary, contain other constituents (for example,in the form of traces linked to the degree of purity of the rawmaterials) in a limited amount (less than 5%, generally less than 2%, inparticular less than 1%) as long as these constituents do not compromisethe desired properties, the composition also advantageously being freeof toxic metals such as lead, mercury, cadmium and hexavalent chromium.

It is surprisingly noted that the enamel according to the invention,based on the aforementioned glass frit, has an expansion coefficient(this coefficient being measured more accurately on the glass frit ofthe enamel, considered to be a glass) of at least 60×10⁻⁷ K⁻¹ (andgenerally higher, in particular at least 80×10⁻⁷ or even 100×10⁻⁷ K⁻¹),i.e. much higher than that of the glass-ceramic substrate. To date, itwas customary to search for enamels having very low expansioncoefficients, close to that of the glass-ceramic substrate, the behaviorof the enamel on the substrate being assumed to be proportionally worsewhen the difference between the expansion coefficients was high.

The enamel chosen according to the invention and the article, inparticular the plate, coated with this enamel have good thermalresistance that is compatible with the use of various types of heaters(induction, radiant, halogen, gas, etc. heaters), are scratch andabrasion resistant and resistant to heat shocks, have good agingresistance and offer, where appropriate (in particular when the frit iscombined with pigments and/or combined with another layer such as alayer of paint as explained below), an excellent compromise between theopacity commonly desired for enamels and the resistance to the variousmechanical stresses to which the coated plates are subjected, theenamel, as desired according to the invention, not affecting, and evenimproving, the mechanical strength of the plates on which the enamel isdeposited, said plates coated with the enamel according to the inventionin particular having one or more mechanical strength properties (whenthe enameled surface is stressed) that are improved (in particularflexural tensile strength and impact resistance) compared to the platescoated with conventional enamels (which in particular breaksystematically in the impact test), as specified and illustrated below.

Contrary to what might have been feared, any interactions between theglass-ceramic and the layer of enamel according to the invention do notcause any damaging modification or disturbance to the surface of theglass-ceramic. From the process standpoint, the composition depositeddoes not differ from a conventional enamel and is completely compatiblewith existing production lines, in particular, it may be applied byscreen printing using standard screen printing machines and fabrics.Moreover, as already indicated, it does not have the drawbacks of aconventional enamel (in particular, little or no weakening of thedecorated face as already mentioned, etc.). Compared with thin layersdeposited by magnetron sputtering, it is more economical and, beingelectrically insulating, it may be used, with no particular adjustment,with touch-sensitive controls, usually capacitive touch-sensitivecontrols. It is also compatible with all types of heating (in particularit withstands the high temperatures, of up to 700° C., of the radiantheating elements, and is suitable for the magnetic fields of inductioncoils, etc.), unlike magnetron-sputtered paints and, where appropriate,layers generally reserved for certain types of heating. It may also bedeposited in any region of the plate (including the heater regions), inparticular unlike paints.

Besides the glass frit (or glass particles) having the compositionexplained previously, the enamel according to the invention may alsocomprise other components. Remember that enamels are generally formed(before application to the substrate and baking) from a powdercomprising a glass frit (that has to form the glassy matrix) andpigments (as colorants in particular, these pigments possibly also beingpart of the frit), the frit and the pigments being based on metaloxides, and from a medium or “carrier” allowing the application and theprior adhesion of the enamel to a substrate.

The enamel according to the invention may thus comprise pigments, thecontent of pigment(s), added to the frit, in the assembly offrit(s)/pigment(s) of the enamel generally being between 20 and 80% byweight (relative to the assembly of frit(s)/pigment(s)), and preferablybetween 40 and 60%. The pigments for enamels may be chosen fromcompounds containing metal oxides such as chromium oxides, copperoxides, iron oxides, cobalt oxides, nickel oxides, zinc oxides,manganese oxides, cerium oxides, titanium oxides, or even based onalumina, etc. or may be chosen from copper chromates, cobalt chromates,etc. They are used as a function of the coloration and/or, whereappropriate, the opacity that it is desired to obtain. One example ofparticularly suitable pigments for adding to the frit according to theinvention is in particular a mixture of iron, chromium, cobalt andnickel oxides.

The glass frit and the pigments are conventionally in powder form beforebeing suspended in a medium. The particle size distribution of theassembly of frit(s)/pigment(s) in powder form is generally chosen sothat at least 90% by weight of the particles forming the powder have adiameter of less than 20 μm, in particular less than 10 μm.

The frit of the composition according to the invention is conventionallyobtained by melting, at high temperature (more than 1000° C.) a mixtureof suitable (natural or synthetic) raw materials. The frit is thenmilled (generally in a solvent, such as ethanol, that is thenevaporated) in powder form, and if necessary pigments and/or opacifiersare added. The pulverulent mixture (glass powder+pigments and/oropacifiers) that results (after evaporation if necessary of the millingsolvent) is subsequently suspended in a medium in order to obtain acomposition (paste) capable of being deposited onto a substrate.

The composition of enamel according to the invention, in itsready-to-deposit form, thus generally also comprises a medium allowingadjustment to the viscosity desired for application to the substrate andenabling binding with the substrate. This medium, chosen in order toensure good suspension of the particles of frits and pigments and thatmust be consumed at the latest during the baking of the enamel, may beany medium or organic binder customarily used in the conventional enamelcompositions and may in particular comprise solvents, diluents, oilssuch as pine oil and other plant oils, resins such as acrylic resins,petroleum fractions, film-forming substances such as cellulosesubstances, etc. The proportion of medium in the ready-to-depositcomposition is preferably between 40 and 60% by weight of saidcomposition, preferably between 45 and 55% by weight.

The enamel composition before deposition onto an article, such as aplate, is therefore generally in the form of a stable liquid-solidmixture, of pasty consistency, with a viscosity suitable for thedeposition process (in particular by screen printing).

The layer of enamel deposited on the article or substrate, in particularthe plate, according to the invention generally covers at least one partof one face of the article (in particular of the plate), in particularthe entire region liable to be exposed to stresses (shock or otherstresses) during use (for example at least the edges or even the mainpart of the face in the case of a plate, the region coated being thereinforced region), and may cover the whole of said face (with theexception, where appropriate, of regions and/or of resists, intended forexample for the reading of displays). The thickness of one layer ofenamel after baking (whether the baking is carried out during theceramization after deposition in the precursor glass, or is carried outsubsequently after deposition on the glass-ceramic, as explained below)is from 1 to 10 μm, generally from 2.5 to 5 μm. In the case inparticular of a plate, the layer defined according to the invention maybe deposited on the lower or upper face of the plate and is preferablydeposited on the lower face.

Advantageously, the enamel may be deposited as one or more layers and/orbe combined, where appropriate, with other layers. In particular, theenamel according to the invention may be used in several layers and/ormay act as an underlayer to another layer, such as a layer of enamel (inparticular of a different nature) or of paint, making it possible inparticular depending on the case to increase the thicknesses and/or tojuxtapose two types of decoration and/or to procure a greater opacity,etc. One embodiment of the invention thus relates to a two-layerenameled article, in particular a plate, that is to say one having, as acoating, at least two layers or passes of enamel, including at least afirst (that is to say deposited first) layer or pass of the enamelaccording to the invention, the enamels of each layer or pass possiblybeing identical or possibly being based on one and the same frit ordifferent, for example possibly being of a different color, one of thelayers or passes forming for example a base frame and the other forminga decoration or specific graphics. Preferably, each novel enamel added,where appropriate, over a previously deposited enamel has a softeningpoint below that of the previously deposited enamel.

Preferably, the enamel may be used with at least one layer of opacifyingpaint. The layer(s) of paint combined, where appropriate, with theenamel according to the invention are advantageously chosen so as towithstand high temperatures and to be stable with respect to their colorand their cohesion with the plate, and so as not to affect themechanical properties of the plate. They advantageously have adecomposition temperature above 350° C., are generally based on one ormore resins (such as a silicone resin, in particular one modified by theincorporation of at least one alkyd resin, or a polyimide, polyamide,polyfluorinated and/or polysiloxane resin, such as the following resins:Dow Corning® 804, 805, 806, 808, 840, 249, 409 HS and 418 HS, Rhodorsil®6405 and 6406 from Rhodia, Triplus® from General Electric Silicone andSILRES® 604 from Wacker Chemie GmbH, etc.), and, where appropriate, theyare filled (for example with one or more pigments or colorants) andoptionally diluted so as to adjust their viscosity, the diluent being,where appropriate, removed during their subsequent baking. The thicknessof each paint layer may be between 1 and 100 microns (especially between5 and 50 microns) and it may be applied by any suitable technique, suchas brush deposition, doctor blade deposition, spraying, electrostaticdeposition, dip coating, curtain coating, screen printing, etc.Generally, according to the invention, it is deposited by screenprinting, where appropriate followed by drying.

Advantageously, the substrate, in particular the glass-ceramic plate,coated with the enamel (obtained after baking) according to theinvention (the enamel if need be comprising pigments and/or beingcombined with a layer of paint, for example) has an opacity such that itmakes it possible in particular to mask underlying elements. The opacityis evaluated in the context of the present invention by measuring(colorimetry in reflection carried out using a Byk-Gardner Color Guide45/0 colorimeter) the color variation ΔE*, corresponding to thedifference between the color measured on the face of the substrateopposite the face bearing the enamel, for the substrate placed on anopaque white background and that for the substrate placed on an opaqueblack background(ΔE*=((L_(B)*−L_(N)*)²+(a_(B)*−a_(N)*)²+(b_(B)*−b_(N)*)²)^(1/2)according to the equation established in 1976 by the CIE, L_(B)*,a_(B)*, b_(B)* being the colorimetric coordinates of the firstmeasurement on a white background and L_(N)*, a_(N)*, b_(N)* being thoseof the second measurement on a black background). Advantageously, theglass-ceramic substrate coated with the enamel according to theinvention has a ΔE* value less than or equal to 0.5, preferably lessthan or equal to 0.4.

As already mentioned, the present invention also relates to theprocesses for manufacturing articles, in particular plates, according tothe invention, and advantageously articles reinforced as mentionedpreviously, in which (when the enamel according to the invention isused) the preceding composition is applied, preferably by screenprinting, to the article of precursor glass (or mother glass or greenglass) before ceramization, said composition being baked during theceramization cycle and/or in which the preceding composition is applied,preferably by screen printing, to the glass-ceramic article afterceramization, then said composition is baked.

Preferably when the baking of the enamel is carried out subsequently(after ceramization, this procedure also being known as a process withrebaking), said baking is carried out at a temperature that makes itpossible to develop crystals in the enamel (generally while modifyingthe interface so that the cracks propagate in and/or beneath theinterface between the glass-ceramic and the enamel parallel to thesurface as indicated previously, the cracks formed in the enamelpropagating and indeed turning after having traveled a few micrometersin and/or beneath the interface so as to finally be parallel to thesurface). This temperature is chosen from the temperature range withinwhich good coverage with the enamel and the formation of crystals are inparticular observed, this temperature range generally lying between 700and 900° C. for the enamels according to the invention. Generally andpreferably, this temperature is around 250° C. to 300° C. higher withrespect to the dilatometric softening temperature of the enamel (or moreprecisely of the glass/of the glass frit forming the enamel), andpreferably corresponds to (or is located just at or inside) theexothermic crystallization peak of the enamel. The enamel covering thesubstrate according to the invention is thus, where appropriate,crystallized after baking.

As a reminder, the manufacture of glass-ceramic plates generally takesplace as follows: the glass, having a composition chosen for forming theglass-ceramic, is melted in a melting furnace, the molten glass is thenrolled into a standard ribbon or sheet, by making the molten glass passbetween rolling rolls, and the glass ribbon is cut to the desireddimensions. The plates thus cut are then ceramized in a manner known perse, the ceramization consisting in firing the plates with the thermalprofile chosen to convert the glass into the polycrystalline materialcalled “glass-ceramic”, the expansion coefficient of which is zero oralmost zero and which is resistant to a heat shock possibly ranging upto 700° C. The ceramization generally comprises a step of progressivelyraising the temperature up to the nucleation range, generally located inproximity to the glass conversion range, a step of passing through thenucleation range over several minutes, a further progressive rise in thetemperature up to the ceramization hold temperature, the ceramizationhold temperature being maintained for several minutes, followed by rapidcooling down to room temperature. Where appropriate, the process alsoincludes a cutting operation (generally before ceramization), forexample using a water jet, mechanical scoring using a scoring wheel,etc., followed by a fashioning operation (grinding, beveling, etc.).

In the process according to the invention, the composition describedpreviously is deposited, either onto the glass precursor article or ontothe glass-ceramic article obtained after ceramization, in the form of apaste, preferably by screen printing, the thickness of the wet filmbeing, for example, around a few microns (in particular less than orequal to 20 μm, and generally less than or equal to 10 μm). Afterdepositing the composition, the coated article is generally dried (forexample, via infrared heating or in an oven), generally at temperaturesaround 100-150° C., so as to evaporate the solvent (medium), fix thecoating and allow the article to be handled, which results in a drycoating, then depending on the case, undergoes a conventionalhigh-temperature ceramization cycle (especially as mentionedpreviously), the baking of the layer accompanying the conversion of thesubstrate, or undergoes a (re)baking at a temperature preferably locatedin the crystallization zone as explained previously, the baking timesbeing adapted as a function of the chosen temperature (for example,longer if the temperature chosen is lower), the coating obtained thenhaving a thickness generally around a few microns (generally between 1and 10 μm, in particular between 2 and 5 μm). The process with(re)baking is generally preferred as it makes it possible to adapt thebaking temperature in a more suitable manner as explained previously andit makes it possible to obtain a greater reinforcement of theglass-ceramic products.

In one embodiment, the article according to the invention may be basedon a glass-ceramic of black appearance, having a low light transmissionof less than 5% (such as the plates sold under the name Kerablack byEurokera) coated with the layer of enamel according to the invention.Preferably however, it is an article, in particular a plate, of agenerally light color, based on a transparent (such as the plates soldunder the name KeraLite by Eurokera and Keraglass) or a translucentglass-ceramic (such as the plates sold under the name Kerawhite,Kerabiscuit or Keravanilla by Eurokera), coated with the layer of enamelaccording to the invention, said layer possibly being of decorativeand/or functional use (for example, possible being intended for masking,at least partly, the underlying elements when they are not in use, suchas heating elements and possible displays, while still allowing theheating elements and possible displays to be detected when they are inuse).

It should be noted that, depending on the number of additional layersrelative to the enamel layer according to the invention, they may bedeposited in succession before and/or after (i.e. in line with orsubsequently to) ceramization, each deposition being generally followedby a heat treatment. It should also be noted that the layer according tothe invention may if required be deposited by a method other than screenprinting.

When the article according to the invention is a plate, said plate may,where appropriate, comprise reliefs and/or hollows and/or it may beprovided (or associated) with one or more additional functional ordecorative elements (frame, connector(s), cable(s), control element(s),display(s), for example what are called “7-segment” light-emitting diodedisplays or liquid crystal displays, electronic control panel withtouch-sensitive controls and digital display, etc.). The plate accordingto the invention may where appropriate be mounted on an insulatingsupport, inside which the one or more heating elements are placed,without an intermediate complex with the aim of masking the interior ofthe apparatus from the user's view.

The invention also relates to the high-temperature-maintaining and/orcooking appliances (or devices) that include at least one substrate(plate or door) according to the invention (for example cookers,built-in cooktops, ovens, etc.). The invention covers both cookingappliances having a single plate and appliances having several plates,each of these plates having, where appropriate, a single heater ormultiple heaters. The term “heater” is understood to mean a cookinglocation. The invention also relates to hybrid cooking appliances, thehob(s) of which has (have) several types of heater. Furthermore, theinvention is not limited to the manufacture of hobs for cookers orcooktops. The plates manufactured according to the invention may, asdescribed above, also be other plates (chimney inserts, fire screens,etc.) that have to be very insensitive to temperature variations.

The following examples illustrate the present invention without howeverlimiting the scope thereof.

A glass-ceramic plate having two smooth faces was manufactured from aglass having a composition according to patent application FR 2 657 079,this in particular comprising, as weight percentages, the followingoxides:

SiO₂ 69.05 Al₂O₃ 18.90 Li₂O 3.3 MgO 0.9 ZnO 1.55 BaO 0.75 K₂O 0.1 TiO₂2.6 ZrO₂ 1.75 As₂O₃ 0.9 Na₂O 0.2

This glass was melted at around 1600-1750° C. in an amount such that aglass ribbon was able to be rolled, from which ribbon glass plates withfinal dimensions of 56.5 cm×56.5 cm×0.4 cm were cut.

The plates were coated by screen printing on their upper face with acomposition, in the form of a screen-printable stable enamel (based on apowder having the composition specified in each of the examples, thepowder being made into a paste in a medium based on acrylic resin and onpine oil sold under the reference MX54 by Ferro for the purpose ofdepositing it onto the plate, and said medium being consumed at thelatest during the baking of the enamel) using conventional polyester orpolyamide fabrics, either before ceramization, or after ceramization asstated subsequently depending on the examples, then dried at around100-150° C.

The plates (before or after coating with the enamel according to theexamples) were ceramized on ceramic trays according to a cycle asdescribed in patent application FR 2 657 079. When the plates werecoated with the enamel after ceramization, they also underwent a bakingoperation after the deposition and drying of the enamel, as statedaccording to the examples.

Glass-ceramic plates coated with a layer of enamel were obtained. Theseplates were cut to form 70 mm×70 mm test specimens, which were analyzedin terms of mechanical strength by measuring their scale factor(expressed in MPa) and also their Weibull modulus by means of aring-on-tripod bending test, the results being interpreted using theWeibull model, as described previously in the present text, thedecorated surface being in extension. The thickness stress profile inthe glass-ceramic was also measured in certain examples using abiasographe as described in the following work: “Photoelasticity ofGlass”, H. Aben, C. Guillemet, Springer-Verlag Berlin Heidelberg 1993,126-129, mentioned above, these profiles appearing in FIGS. 1, 2 and 3,these figures respectively illustrating the stress profiles in thethickness for the following examples: reference example 3, example 1 andexample 2; FIGS. 1 and 2 also illustrating the thickness stress profilein the case of the bare (uncoated) glass-ceramic plates used.

Reference Example 1

In the first reference example, the enamel used was a standard enamelbased on a powder comprising 70% by weight of a glass frit having thefollowing composition: SiO₂: 41.7%; Na₂O: 0.9%; K₂O: 3.5%; Li₂O: 2.1%;CaO: 2.8%; Al₂O₃: 18.5%; ZrO₂: 2.4%; B₂O₃: 28%, said powder alsocomprising 30% by weight of TiO₂ as pigment. The enamel (morespecifically the glass frit forming said enamel) according to thepresent example had an expansion coefficient of the order of 52×10⁻⁷K⁻¹, and said enamel (or rather the glass frit forming said enamel) alsohad a dilatometric softening temperature of the order of 590° C. In thisreference example, the enamel was deposited on the plate (of precursorglass or green glass or mother glass) before ceramization and bakedduring the ceramization, the thickness of the enamel layer after bakingbeing around 3 μm.

The scale factor obtained (according to the Weibull model, after abending test) was around 52 MPa, the Weibull modulus being equal to 13.

Reference Example 2

In the second reference example, the enamel used was a standard enamelbased on a powder comprising 100% by weight of the glass frit describedin reference example 1 (the expansion coefficient and the dilatometricsoftening temperature of the enamel being of the same order as inreference example 1). In this second example, the enamel was depositedon the already ceramized plate, the assembly being (re)baked at 800° C.for 30 minutes, the thickness of the enamel layer after baking beingaround 3 μm.

The scale factor obtained was around 80 MPa, the Weibull modulus beingequal to 54.

Reference Example 3

In this third reference example, the enamel used was a standard enamelbased on a powder comprising 100% by weight of a glass frit having thefollowing composition: SiO₂: 48.6%; MgO: 3.8%; Na₂O: 2.6%; K₂O: 3.3%;Li₂O: 1.3%; CaO: 0.6%; BaO: 17.8%; Al₂O₃: 7.1%; ZrO₂: 1.7%; ZnO: 8%;B₂O₃: 5.4%. The enamel according to the present example had an expansioncoefficient of the order of 75×10⁻⁷ K⁻¹ and a dilatometric softeningtemperature of the order of 600° C. In this third example, the enamelwas deposited on the plate (green glass or mother glass) beforeceramization and baked during the ceramization, the thickness of theenamel layer after baking being around 3 μm.

The scale factor obtained was around 88 MPa, the Weibull modulus beingequal to 27. The thickness stress profile in the glass-ceramic is givenin FIG. 1, in which the presence of a maximum tension in proximity tothe enameled surface is not observed, the maximum stress value beingaround 0.9 MPa. In comparison, the stress profile of an uncoated plateis represented, this profile also not having a maximum tension inproximity to the enameled surface, such a plate having a scale factor ofaround 170 MPa.

Example 1

In this first example according to the invention, the enamel used was anenamel based on a powder comprising 100% by weight of a glass frithaving the following composition: SiO₂: 60.5%; MgO: 4%; Na₂O: 9.5%;Li₂O: 5%; BaO: 10%; ZrO₂: 2%; ZnO: 4%; B₂O₃: 5%. The enamel according tothe present example had an expansion coefficient of the order of100×10⁻⁷ K⁻¹ and a dilatometric softening temperature of the order of523° C. In this first example, the enamel was deposited on the plate(green glass or mother glass) before ceramization and baked during theceramization, the thickness of the enamel layer after baking being ofthe order of 3 μm.

The scale factor obtained was around 180 MPa, the Weibull modulus beingequal to 27. The thickness stress profile in the glass-ceramic is givenin FIG. 2, in which the presence of a peak is observed that has amaximum tensile stress of 3.0 MPa at a depth (measured perpendicular tothe surface) of 0.45 mm beneath the surface (starting from the enameledside/side reinforced by the enamel). In comparison, the stress profileof an uncoated plate is represented, this profile not having a maximumtension in proximity to the enameled surface, as already indicated inreference example 3.

Example 2

In this second example according to the invention, the enamel used wasthe same enamel as in the preceding example 1 according to theinvention, the enamel this time being deposited on the already ceramizedplate, the assembly being (re)baked at 770° C. for 30 minutes, thethickness of the enamel layer after baking being around 3 μm.

The scale factor obtained was around 207 MPa, the Weibull modulus beingequal to 19.

The thickness stress profile in the glass-ceramic is given in FIG. 3, inwhich the presence of a maximum tension and of a flexion is observed,with a maximum tensile stress of 3.1 MPa at a depth of 0.7 mm beneaththe surface (starting from the enameled side/side reinforced by theenamel).

Example 3

In this third example according to the invention, the enamel used wasbased on a powder comprising 45% by weight of the glass frit describedin the preceding example 2 according to the invention, said powder alsocomprising 55% by weight of black pigments in the form of a mixture ofiron, chromium, cobalt and nickel oxides, (the expansion coefficient andthe dilatometric softening temperature of the enamel being of the sameorder as in example 1 according to the invention). The enamel wasdeposited on the already ceramized plate and baked as in example 2according to the invention, the thickness of the enamel layer afterbaking being around 6.75 μm.

The scale factor obtained was around 238 MPa, the Weibull modulus beingequal to 20, and the color variation ΔE* of the enameled plate obtainedwas around 0.04. A maximum tensile stress of 2.0 MPa was observed at adepth of 0.64 mm beneath the surface (starting from the enameledside/side reinforced by the enamel).

Example 4

In this fourth example according to the invention, the enamel used wasan enamel based on a powder comprising 100% by weight of a glass frithaving the following composition: SiO₂: 63%; MgO: 4%; Na₂O: 9.5%; Li₂O:2.5%; BaO: 10%; ZrO₂: 2%; ZnO: 4%; B₂O₃: 5%. The enamel according to thepresent example had an expansion coefficient of the order of 87×10⁻⁷ K⁻¹and a dilatometric softening temperature of the order of 549° C. In thisfourth example, the enamel was deposited on the already ceramized plate,the assembly being (re)baked at 800° C. for 30 minutes, the thickness ofthe enamel layer after baking being around 4 μm.

The scale factor obtained was around 262 MPa, the Weibull modulus beingequal to 16.

The plates according to the invention may especially be usedadvantageously to produce a new range of hobs for cookers or cooktops,or for producing elements of a wall or walls (for example doors) forovens, or for producing chimney inserts or fire screens, etc.

The invention claimed is:
 1. A glass-ceramic article, wherein saidarticle is at least partly coated with at least one layer of an enamelformed from a glass frit comprising, as weight percentages: SiO₂ 50-66%;MgO 3-8%; Na₂O 7-15%; K₂O 0-3%; Li₂O 0-12%; CaO 0-10%; BaO 0-15%; Al₂O₃0-3%; ZrO₂ 0-3%; ZnO 0-5%; and B₂O₃ 0-8%,

wherein the sum of alkaline-earth metal oxides, CaO+BaO, is between 8and 15%, and the sum of alkali metal oxides, Na₂O+K₂O+Li₂O, is between 7and 20%.
 2. The glass-ceramic article as claimed in claim 1, wherein theglass fit comprises less than 2% of alumina Al₂O₃.
 3. The glass-ceramicarticle as claimed in claim 1, wherein the article is further at leastpartly coated with at least one layer of opacifying paint, at least oneadditional layer of enamel, or any combination thereof.
 4. Theglass-ceramic article as claimed in claim 1, having a scale factor,obtained according to the Weibull model, after a bending test, of atleast 130 MPa.
 5. The glass-ceramic article as claimed in claim 1,wherein the enamel is crystalline.
 6. The glass-ceramic article asclaimed in claim 1, wherein a crack formed during a shock is orientedparallel to the surface.
 7. The glass-ceramic article as claimed inclaim 1, as a 3-mm thick glass-ceramic plate.